KUKA KR 15 DELTA-2 Assembly Manual

Product Description

System composition

Robot arm body+KR C5 S6 control cabinet+smartPAD-2 teaching pendant+motor cable, data cable+system software+optional accessories.

Mechanical body structure (4-axis Delta)

A1/A2/A3: Three drivers for the upper arm; A4: End rotation axis; The components include upper arm, forearm, movable end platform, spring assembly, and base frame;

Electrical components: RDC digital converter, motor cables, encoder cables;

The spring component has a huge elastic potential energy, and there is a risk of platform falling during disassembly and assembly operations.

Designated use and prohibition of misuse

Purpose: Workpiece and tool picking and handling, packing and sorting, must be used within the specified environmental parameters.   

Prohibition: manned/animal, climbing pedals; Outdoor, explosion-proof, and radioactive environments; Unauthorized modification of the main structure by KUKA (resulting in direct loss of warranty); The main body cannot be directly put into operation independently and must be integrated into the entire set of equipment.

Safety

Legal responsibility: Declaration of incorporation attached to the entity; The overall risk assessment, EC conformity declaration, CE marking, and terminal operation manual are all the responsibility of the system integrator; Unauthorized modification of the main body shall be the sole responsibility of the user/integrator.

Personnel classification: integrators, operators, debuggers, maintenance and repair personnel; Deep ontology maintenance is only available to authorized personnel of KUKA.

Area Definition

Workplace: Robot’s movable range;

Dangerous area=workspace+parking distance, must be physically fenced for protection; Without physical protection, it must fully meet all the requirements of EN   ISO   10218 collaborative robots.

protective device

Mechanical hard limit: A1-A3 axis configuration; After hitting the hard limit, the machine must be stopped to contact the KUKA and cannot be directly reused;

Optional adjustable mechanical shaft limit and brake release device;

The body nameplate and warning label are strictly prohibited from being removed or altered.

Core Security Points

There is a risk of brake failure and falling after power failure; It is strictly prohibited for personnel to stand directly below the robot; Before maintenance, place the mechanism in a safe position and increase mechanical support if necessary.

The motor brake generates an electromagnetic field; Personnel wearing active implantable devices such as pacemakers should maintain a distance of ≥ 300mm from the body (both power on and power-off are effective).

After the teaching pendant is disconnected, its emergency stop fails, and the disconnected teaching pendant must be removed from the work site; Enable the switch function to be tested at least once every 12 months.

After modifying hardware, software, and parameters, all programs must undergo low-speed testing in T1 mode; The simulation generation program must also undergo T1 actual testing.

Repair live parts: If only pressing the emergency stop button is insufficient, the main power switch must be disconnected and the power must be checked to confirm the power outage; After the controller is powered off, the internal high-voltage capacitor still maintains high voltage for several minutes.

Fault handling: Power off, lock and tag, post fault warning labels; Perform a full set of safety function verification after fault repair.

Technical Data (KR15 D1200-2/KR15 D1600-2)

Parameters KR   15   D1200-2 KR   15   D1600-2

Number of axes: 4 axes, 4 axes

Rated load 8   kg 8   kg

Maximum load 15   kg 15   kg

Maximum working diameter 1200   mm 1600   mm

The weight of the body is about 95 kg

Protection level IP65 IP65

Noise<77   dB (A)<77   dB (A)

Installation method limited to ceiling lifting only

Repeat positioning XY ± 0.04 mm ± 0.04 mm

Z repeated positioning ± 0.04   mm ± 0.04   mm

R rotation repeat positioning ± 0.025 °± 0.025 °

Controller KR C5 S6 KR C5 S6

Operating under environmental conditions of 0-45 ℃; Storage -25~+60 ℃, environmental level 3K22 operation 0~45 ℃; Storage -25~+60 ℃, environmental level 3K22

Axis motion range: A1/A2/A3: -80 °~+40 °; A4：±355°； Comes with standard beat time data.

A4 flange: 7 × M6 thread, locating pin Φ 6   H7; the flange provides normal operating load and emergency stop impact load.

Load verification: The load mass and moment of inertia Iz (maximum 0.22 kg · m ²) must be verified simultaneously, and the load data must be entered into the controller. The manual provides a load curve diagram, with the center of gravity based on the A4 flange end face.

Base lifting load: including the self weight of the body and the load, the maximum load value must be taken for the design of the ceiling frame.

Shutdown distance/shutdown time: STOP0, STOP1, provide X/Y/Z directional charts; The manual values are for reference only, and the actual working conditions on the project site must be measured for the shutdown distance.

REACH Article 33 compliance; Specification for identification of body nameplates.

Project Planning

Lifting frame: Users can process hexagonal transition plates themselves; Bolt specification: 12 M8 × 30-8.8 bolts for robot fixation; 9 M16 × 40-8.8 transition plates fixed;

The minimum anti-interference distance between the upper arm and the structure is 300mm; The robot is recommended to be inclined relative to the conveyor line to optimize the load.

Cable planning

Motor cable X30, data cable X31; Optional cable lengths of 7   m/15   m/25   m are allowed, with a maximum extension of one section allowed. Splicing of more than two sections is prohibited;

Static minimum bending radius: motor cable ≥ 85mm; data cable ≥ 41mm;

Users need to configure equipotential grounding conductors and separate wiring to meet EMC requirements; Avoid cable tension to prevent tripping risks.

A4 cable assembly: Strictly position the cable clamp according to the drawing, torque M4 screw 1.2   Nm.

Transportation

The robot must enter the designated transport posture (A1=50 °, A2=50 °, A3=50 °, A4=0 °);

Two ways of handling: forklift handling of original packaging boxes; Lifting ring+crane lifting body; Dismantle tools and tie cables before lifting;

Avoid impact and vibration during transportation, and do not drag cables.

Startup and Re commissioning (Ceiling Lifting Process)

User frame fixed hexagonal transition plate; Maintain the transport posture of the crane body, position the locating pin, and tighten the M8 bolts diagonally;

Wiring: Install equipotential grounding, motor cables, and data cables; Add magnetic rings to the data cable and conduct equipotential continuity testing;

Release the brake and adjust the upper arm to a horizontal position;

Forearms must be disassembled and assembled individually, and it is strictly prohibited to remove all three forearms at the same time to prevent the end platform from falling; Spring components must not be pulled forcefully;

Assemble the entire A4 cable assembly and strictly install all cable clamps according to the drawings;

Pre power on checklist: mechanical fastening, cables, grounding; Change the factory default password; Test run all programs in T1 mode.

Maintenance

Emergency stop, power off, lock and tag must be carried out before maintenance.

Maintenance cycle maintenance project

Recheck the tightening torque of the base bolts after 100 hours

Replace bearings and bushings within 5000 hours or no later than 1 year; Replace the spring component

20000 hours or at the latest 5 years of forearm appearance inspection (replace immediately if cracks appear); Visual inspection of A4 cable assembly, if damaged, please contact KUKA for replacement

Tip: After replacing the spring, bearing, and cable assembly, zero calibration is required.

Maintenance

Only authorized personnel from KUKA are allowed to perform deep disassembly and maintenance of the main body;

After the component replacement is completed, complete safety testing+zero calibration Mastering.

Discontinuation, Storage, and Scrap Disposal

Deactivation: Adjust the mechanism to transport posture; Remove the A4 cable assembly and forearm in sequence, and disassemble the entire machine;

Storage: Dry and dust-free, avoiding condensation; Sealed electrical connectors; Use protective film and desiccant for protection;

Scrap classification: Motors and RDC circuit boards are treated as electronic waste, and it is prohibited to disassemble the motor gearbox by oneself; Carbon fiber/aluminum alloy/steel mechanical parts, seals, and cables are classified as industrial waste; Complete list of gear oil, lubricating grease, and sealant material grades.